Pallet container

ABSTRACT

A pallet container having eight side walls, a bottom piece, two leg flaps that are used to automatically deploy the container from a flat, collapsed position, and a series of inside folds and outside folds. The pallet container is constructed from one or more blanks made of cardboard. The blanks used to make the pallet container may have different configurations. The pallet container has an open and a closed position and can be converted from one position to the other by a single person without the need of special tools or equipment. A cardboard blank for making the pallet container is also disclosed.

PRIORITY CLAIM

This application is a continuation application of U.S. patentapplication Ser. No. 16/230,479, filed Dec. 21, 2018 and now U.S. Pat.No. 11,161,645, which is a continuation application of U.S. patentapplication Ser. No. 14/888,286, filed Oct. 30, 2015 and now U.S. Pat.Number 10,160,568, which is a United States National Stage Applicationof Patent Cooperation Treaty Application No. PCT/US14/36014, filed Apr.30, 2014, which claims priority to U.S. Provisional Patent ApplicationNo. 61/817,419, filed Apr. 30, 2013, the disclosures of which areincorporated herein by reference in their entireties.

TECHNICAL FIELD

The present invention relates to cardboard containers and, moreparticularly, to cardboard containers utilized on conventional pallets.

BACKGROUND ART

Numerous corrugated containers have been proposed over the years forconfining and protecting heavy or bulky palletized loads. Wooden palletsare in widespread use in industrial or warehouse environments where theyare stacked upon one another until use, and thereafter forciblymanipulated and moved about by powerful fork-lift trucks. Duringtransit, these heavily laden pallets are routinely subjected tomechanical stresses and shocks as they are aggressively and sometimescarelessly moved about during typical loading and unloading operations.A variety of heavy duty, corrugated boxes have been designed strictlyfor pallet use. Many of these fold together and have a plurality oflocking straps or flaps that interconnect with portions of the pallet.Most have a base that engages the pallet with an upright, generallytubular body that is polygonal in shape (octagonal and hexagonalconfigurations are the most common).

Many of the prior art large-capacity pallet boxes must be invertedbefore unfolding. Either the box must be handled by two workers, or oneworker must push it against a wall or similar stationary object to forceit to deploy. Typically, six to eight flaps must be manually aligned andinterfitted with two or more major flaps on the bottom locking thedevice together. Once the main bottom flaps are locked, the box isturned over for use. Some boxes of this description are so flimsy thatthe mere act of flipping them over forces the box apart, necessitatingre-assembly prior to loading. Pallet boxes are used in various foodindustries and may be filled with a thousand or more pounds of meatproduct such as chicken, beef, or pork.

Because of these heavy loads, the prior art pallet containers are alsosusceptible to bulging on all sides. The bulging often prevents the mosteconomical packing of pallets and transport of the containers, whichresults in higher shipping costs. In some cases, the bulging can causecollapse of the container and result in spillage of the contents of thecontainers.

It would therefore be desirable to develop a pallet container that isdurable, not susceptible to bulging, and can be easily deployed from aflat state by a single person without the need of special tools orequipment.

DISCLOSURE OF INVENTION

The pallet container of the present invention has eight side walls, abottom piece, two leg flaps that are used to automatically deploy thecontainer from a flat, collapsed position, and a series of inside foldsand outside folds. The pallet container is constructed from one or moreblanks made of cardboard. The blanks used to make the pallet containermay have different configurations. The pallet container has an open anda closed position and can be converted from one position to the other bya single person without the need of special tools or equipment.

These and other features, objects and advantages of the presentinvention will become better understood from a consideration of thefollowing detailed description of the preferred embodiments and appendedclaims in conjunction with the drawings as described following:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flat plan view of the blank of the first embodiment of thepresent invention.

FIG. 2 is a perspective view of the blank of FIG. 1 partially foldedalong score line 120.

FIG. 3 is a perspective view of the blank of FIG. 1 completely foldedalong score line 120.

FIG. 4 is a perspective view of the blank of FIG. 3 partially foldedalong score line 118.

FIG. 5 is a perspective view of the blank of FIG. 4 with glue flap 58joined to eighth wall 26 and glue flap 60 joined to outside fold 76.

FIG. 6 is a perspective view of the pallet container constructed fromthe blank of FIG. 1 with the top of the container in the open position.

FIG. 7 is a perspective view of the pallet container of FIG. 6 with theinside flaps folded along score lines 88 and 96.

FIG. 8 is a perspective view of the bottom of the pallet container ofFIG. 6 with bottom flap 30 joined to bottom flap 32.

FIG. 9 is a perspective view of the top of the pallet container of FIG.6 with leg flap 36 folded underneath the bottom piece of the palletcontainer.

FIG. 10 is a perspective view of the top of the pallet container of FIG.6.

FIG. 11 is a perspective view of the bottom of the pallet container ofFIG. 6 in the deployed position.

FIG. 12 is a perspective view of the bottom of the pallet container ofFIG. 6 transitioning from the deployed position to the collapsedposition.

FIG. 13 is a perspective view of the pallet container of FIG. 6 in thecollapsed position.

FIG. 14 is a flat plan view of the blank of the second embodiment of thepresent invention.

FIG. 15 is a perspective view of the pallet container constructed fromthe blank of FIG. 14 with the inside flaps folded along score lines 88and 96.

FIG. 16 is a perspective view of the bottom of the pallet container ofFIG. 15 with bottom flap 30 joined to bottom flap 32.

FIG. 17 is a perspective view of the bottom of the pallet container ofFIG. 16 with the free ends of leg flaps 34, 36 being inserted into slots210.

FIG. 18 is a perspective view of the bottom of the pallet container ofFIG. 16 with the free ends of the leg flaps 34, 36 inserted into slots210.

FIG. 19 is a cross-section view of the FIG. 18 with the free end of legflap 36 in the interior of the pallet container in the unlockedposition.

FIG. 20 is a cross-section view of FIG. 18 with the free end of leg flap36 in the interior of the pallet container in the locked position inslot 212.

FIG. 21 is a flat plan view of the blank of the third embodiment of thepresent invention.

FIG. 22 is a perspective view of the blank of FIG. 21.

FIG. 23 is a perspective view of the blank of FIG. 21 partially foldedalong score line 78.

FIG. 24 is a perspective view of the blank of FIG. 23 partially foldedalong score line 308.

FIG. 25 is a perspective view of the blank of FIG. 24 with the insideflaps folded along score lines 88 and 96.

FIG. 26 is a perspective view of the pallet container constructed fromthe blank of FIG. 21 with glue flap 302 joined to sixth wall 22 and glueflap 304 joined to outside fold 74.

FIG. 27 is a perspective view of the pallet container of FIG. 26 withglue flap 302 joined to sixth wall 22 and glue flap 304 joined tooutside fold 74.

FIG. 28 is a perspective view of the pallet container of FIG. 26 in thedeployed position.

FIG. 29 is a perspective view of the bottom of the pallet container ofFIG. 26 transitioning from the deployed position to the collapsedposition.

FIG. 30 is a perspective view of the pallet container of FIG. 26 in thecollapsed position.

FIG. 31 is a flat plan view of the blanks of the fourth embodiment ofthe present invention.

FIG. 32 is a flat plan view of the blanks of FIG. 31.

FIG. 33 a flat plan view of blank 400 joined to blank 420.

FIG. 34 is a perspective view of blank 400 joined to blank 420.

FIG. 35 is a perspective view of the blanks of FIG. 34 partially foldedalong score line 78.

FIG. 36 is a perspective view of the blanks of FIG. 34 partially foldedalong score lines 48, 50, 52, 54, 56.

FIG. 37 is a perspective view of the pallet container constructed fromthe blanks of FIG. 31 with glue flap 58 joined to eighth wall 26 andglue flap 60 joined to outside fold 76.

FIG. 38 is a perspective view of the pallet container of FIG. 37 in thedeployed position.

FIG. 39 is a flat plan view of the blanks of the fifth embodiment of thepresent invention.

FIG. 40 is a flat plan view of the blanks of FIG. 39.

FIG. 41 is a flat plan view of blank 500 joined to blank 420.

FIG. 42 is a flat plan view of the blanks of the sixth embodiment of thepresent invention.

FIG. 43 is a flat plan view of the blanks of FIG. 42.

FIG. 44 is a flat plan view of blank 600 joined to blank 602 and blank420 joined to blank 600.

FIG. 45 is a flat plan view of the blanks of the sixth embodiment of thepresent invention.

FIG. 46 is a flat plan view of blank 700 joined to blank 720.

FIG. 47 is a perspective view of the blanks of FIG. 46 partially foldedalong score line 120.

FIG. 48 is a perspective view of the blanks of FIG. 46 completely foldedalong score line 120.

FIG. 49 is a perspective view of the blank of FIG. 46 partially foldedalong score line 118.

FIG. 50 is a perspective view of the blanks of FIG. 49 with glue flap 58joined to eighth wall 26 and glue flap 60 joined to outside fold 76.

FIG. 51 is a perspective view of the pallet container constructed fromthe blanks of FIG. 43 with the top of the container in the openposition.

FIG. 52 is a perspective view of the pallet container of FIG. 51 withthe inside flaps folded along score lines 88 and 96.

FIG. 53 is a perspective view of the bottom of the pallet container ofFIG. 51 with bottom flap 30 joined to bottom flap 32.

FIG. 54 is a perspective view of the top of the pallet container of FIG.51 with leg flap 36 folded underneath the bottom piece of the palletcontainer.

FIG. 55 is a perspective view of the top of the pallet container of FIG.51.

FIG. 56 is a perspective view of the bottom of the pallet container ofFIG. 51 in the deployed position.

FIG. 57 is a perspective view of the bottom of the pallet container ofFIG. 51 transitioning from the deployed position to the collapsedposition.

FIG. 58 is a flat plan view of the blank of the eighth embodiment of thepresent invention.

FIG. 59 is a perspective view of the blank of FIG. 58 partially foldedalong score line 52.

FIG. 60 is a perspective view of the blank of FIG. 58 completely foldedalong score line 52.

FIG. 61 is a perspective view of the blank of FIG. 60 partially foldedalong score line 44.

FIG. 62 is a perspective view of the blank of FIG. 60 completely foldedalong score line 44.

FIG. 63 is a perspective view of the pallet container constructed fromthe blank of FIG. 58 with the top of the container in the open position.

FIG. 64 is a perspective view of the pallet container of FIG. 63 withtop of the container in the open position.

FIG. 65 is a perspective view of the bottom of the pallet container ofFIG. 63 with bottom flap 802 joined to bottom flap 808.

FIG. 66 is perspective view of the top of the pallet container of FIG.63 with leg flap 36 folded underneath the bottom piece of the palletcontainer.

FIG. 67 is a perspective view of the top of the pallet container of FIG.63.

FIG. 68 is a perspective view of the bottom of the pallet container ofFIG. 63 in the deployed position.

FIG. 69 is a perspective view of the bottom of the pallet container ofFIG. 63 transitioning from the deployed position to the collapsedposition.

FIG. 70 is a flat plan view of the blank of the ninth embodiment of thepresent invention.

FIG. 71 is a perspective view of the blank of FIG. 70 partially foldedalong score line 52.

FIG. 72 is a perspective view of the blank of FIG. 70 completely foldedalong score line 52.

FIG. 73 is a perspective view of the blank of FIG. 72 partially foldedalong score line 44.

FIG. 74 is a perspective view of the blank of FIG. 72 completely foldedalong score line 44.

FIG. 75 is a perspective view of the pallet container constructed fromthe blank of FIG. 70 with the top of the container in the open position.

FIG. 76 is a perspective view of the bottom of the pallet container ofFIG. 75 with bottom flap 802 joined to bottom flap 808.

FIG. 77 is a perspective view of the top of the pallet container of FIG.75 with leg flap 904 folded underneath the bottom piece of the palletcontainer. FIG. 78 is a perspective view of the top of the palletcontainer of FIG. 75.

FIG. 79 is a perspective view of the bottom of the pallet container ofFIG. 75 in the deployed position.

FIG. 80 is a perspective view of the bottom of the pallet container ofFIG. 75 transitioning from the deployed position to the collapsedposition.

FIG. 81 is a flat plan view of the blank of the tenth preferredembodiment.

FIG. 82 is a perspective view of the blank of FIG. 81 partially foldedalong score line 52.

FIG. 83 is a perspective view of the blank of FIG. 81 completely foldedalong score line 52.

FIG. 84 is a perspective view of the blank of FIG. 83 partially foldedalong score line 44.

FIG. 85 is a perspective view of the blank of FIG. 83 completely foldedalong score line 44.

FIG. 86 is a perspective view of the pallet container constructed fromthe blank of FIG. 81 with the top of the container in the open position.

FIG. 87 is a perspective view of the pallet container of FIG. 86 withbottom flap 802 joined to bottom flap 808.

FIG. 88 is a perspective view of the bottom of the pallet container ofFIG. 86 in the deployed position.

FIG. 89 is a perspective view of the pallet container of FIG. 86 in thecollapsed position.

FIG. 90 is a perspective view of the pallet container of FIG. 86 withthe top of the container in the open position with the cap beinginserted.

FIG. 91 is a perspective view of the pallet container of FIG. 86 withcap inserted into the top of the container.

FIG. 92 is a perspective view of the pallet container of FIG. 91 withthe flaps 1002, 1004, 1006, 1008, 1010, 1012, 1014, 1016 folded alongscore line 1056 forming rim 1058.

FIG. 93 is a flat plan view of the blanks of the eleventh preferredembodiment of the present invention.

FIG. 94 is a flat plan view of blank 1100 joined to blank 1102.

FIG. 95 is a perspective view of the joined blanks of FIG. 94 completedfolded along score line 44.

FIG. 96 is a perspective view of the pallet contain constructed from theblanks of FIG. 93.

FIG. 97 is a perspective view of the bottom of the pallet container ofFIG. 96 with bottom flap 1112 joined to bottom flap 1114.

FIG. 98 is a perspective view of the bottom of the pallet container ofFIG. 96 in the deployed position.

FIG. 99 is a perspective view of the bottom of the pallet container ofFIG. 96 transitioning from the deployed position to the collapsedposition.

BEST MODE FOR CARRYING OUT THE INVENTION

With reference to FIGS. 1-99, the preferred embodiments of the presentinvention may be described. The pallet container 10 has eight side walls12, 14, 16, 18, 20, 22, 24, 26, a bottom piece 28, two leg flaps 34, 36that are used to automatically deploy the container 10 from a flat,collapsed position (or a closed position), and a series of inside foldsand outside folds. The pallet container 10 is constructed from a blankmade of cardboard. The preferable size of the container 10 will varybased on the goods being transported in the container 10.

As described herein, the pallet container 10 can be constructed fromblanks having different configurations.

In the first preferred embodiment, as shown in FIGS. 1-13, the blank 100has a first row 38 and a second row 40. The first row 38 is comprised ofa glue flap 58, a first wall 12, a second wall 14, a third wall 16, afourth wall 18, a fifth wall 20, a sixth wall 22, a seventh wall 24, andan eighth wall 26. The glue flap 58, first wall 12, second wall 14,third wall 16, fourth wall 18, fifth wall 20, sixth wall 22, seventhwall 24, and eighth wall 26 are all preferably rectangular in shape. Theglue flap 58 is joined to the first wall 12 via a score line 42.Similarly, the first wall 12 is joined to the second wall 14 via scoreline 44, the second wall 14 to the third wall 16 via score line 46, thethird wall 16 to the fourth wall 18 via score line 48, the fourth wall18 to the fifth wall 20 via score line 50, the fifth wall 20 to thesixth wall 22 via score line 52, the sixth wall 22 to the seventh wall24 via score line 54, and the seventh wall 24 to the eighth wall 26 viascore line 56.

The first row 38 is joined to the second row 40 along score line 78. Thesecond row 40 of blank 100 is comprised of a glue flap 60, an insidefold 62, a first leg flap 34, an inside fold 64, an outside fold 66, afirst bottom flap 30, an outside fold 68, an inside fold 70, a secondleg flap 36, an inside fold 72, an outside fold 74, a second bottom flap32, and an outside fold 76.

The glue flap 60 is joined to the inside fold 62 along score line 42.First leg flap 34 is joined to inside fold 62 along score line 80 on oneside and joined to inside fold 64 along score line 82 on the other side.Inside fold 64 is joined to outside fold 66 along score line 44. Firstbottom flap 30 abuts, but is not joined to, the outside fold 66 on oneside and the outside fold 68 on the other side. The outside fold 68 isjoined to the inside fold 70 along score line 50. The second leg flap 36is joined to inside fold 70 along score line 84 on one side and toinside fold 72 along score line 86 on the other side. Inside fold 72 isjoined to outside fold 74 along score line 52. Second bottom flap 32abuts, but is not joined to, the outside fold 74 on one side and theoutside fold 76 on the other side. The inside folds 62, 64, 70, 72 aretriangular-shaped, preferably in the shape of a right triangle.

The first bottom flap 30 and second bottom flap 32 are preferably in theshape of pentagon. The top side of the flaps 30, 32 is along score line78. The bottom side (or free side) of the flaps 30, 32 is parallel tothe top side. Joined to the two parallel left and right sides of thefirst bottom flap 30 via score lines 88 are inside flaps 90. Joined tothe bottom side of the flap 30 via score line 92 is glue flap 94. Joinedto the two parallel sides of the second bottom flap 32 via score lines96 are inside flaps 98.

As shown in FIGS. 2-8, to construct the pallet container 10 from theblank 100 of the first embodiment, the glue flap 58 is attached toeighth wall 26 and the eight walls are folded inward along the scorelines 42, 44, 46, 48, 50, 52, 54, 56 of the first row 38 to form theoctagon opening 122 of the container 10. Glue flap 58 is preferablyglued to the exterior surface of the eighth wall 26. Glue flap 60 of thesecond row 40 of the blank 100 is similarly attached to the outside fold76. When glue flaps 58, 60 are attached to the eighth wall 26, scoreline 42 is aligned with side edge of the eighth wall 26.

The bottom piece 28 of the container is formed by joining bottom flaps30, 32 via glue flap 94. The glue flap 94 of the first bottom flap 30 ispreferably glued to the exterior surface of second bottom flap 32. Asshown in FIG. 9, when the container is the open position, the insideflaps 90, 98 are bent upward along score lines 88, 96. One inside flap90 and one inside flap 98 are positioned end-to-end and abut first wall12 in the interior of the container 10. Similarly, one inside flap 90and one inside flap 98 are positioned end-to-end and abut the fifth wallin the interior of the container 10. The inside flaps 90, 98 serve toseal the interior of the container 10.

The deployment process of converting the container 10 from a flatposition (as shown in FIG. 13) to a fully deployed container in the openposition (as shown in FIG. 10) comprises two steps. The first step isthe top opening process. In the flat position, the container 10 iscollapsed on itself. For example, third wall 16 is collapsed on seventhwall 24. Folded between third wall 16 and seventh wall 24 is bottompiece 28. First bottom flap 30 is folded on second bottom flap 32 alongscore line 92. The first wall 12 and fifth wall 20 are folded in halfalong score lines 118, 120. To deploy the container from this flatposition, the user pushes the first wall 12 and fifth wall 20 towardseach other. This action transitions the container 10 into the openposition as shown in FIG. 12. An opening 122 in the top end of thecontainer 10 is created by the eight joined walls 12, 14, 16, 18, 20,22, 24, 26. In addition, the bottom piece 28 unfolds along score line92.

The second step of the deployment process is the bottom closing process.With the container 10 in the upright position as shown in FIG. 9, theuser exerts downward pressure on the first leg flap 34 and the secondleg flap 36, preferably in a rocking motion. As pressure is exerted onthe first leg flap 34 and the second leg flap 36, the leg flaps 34, 36fold under the bottom piece of the container 10 along score line 78.During the folding process of first leg flap 34, as shown in FIG. 11,outside fold 76 (connected to glue flap 60) is forced to fold on top offirst leg flap 34 along score lines 78, 42, and 80. Thus, inside fold 62is folded between outside fold 76 and first leg flap 34. Similarly,outside fold 66 is forced to fold on top of first leg flap 34 alongscore lines 78, 44, and 82. Thus, inside fold 64 is folded betweenoutside fold 66 and the first leg flap 34. During the folding process ofsecond leg flap 36, outside fold 68 is forced to fold on top of secondleg flap 36 along score lines 78, 50, and 84. Thus, inside fold 70 isfolded between outside fold 68 and second leg flap 36. Similarly,outside fold 74 is forced to fold on top of second leg flap 36 alongscore lines 78, 52, and 86. Thus, inside fold 72 is folded betweenoutside fold 74 and second leg flap 36. In application, the weight ofthe load inside the container 10 holds the first leg flap 34 and thesecond leg flap 36 parallel with bottom piece 28, and thus allows theflaps 34, 36 to serve as reinforcement to the bottom piece 28 of thecontainer.

To convert the container 10 back from the open position to the closedposition, first wall 12 and fifth wall 20 are pulled outward and awayfrom one another. This causes the container 10 to collapse along scoreline 118 and score line 120. The bottom piece 28 also folds inward alongscore line 92. The deployment and collapsing process can easily beperformed by a single person.

In addition to being utilized in the deployment and collapsingprocesses, score lines 118, 120 provide an advantage over prior artcontainers by preventing the risk of bulging on all sides of thecontainer 10. By being susceptible to bulging along score lines 118,120, bulging at the third wall 16 and/or seventh wall 20 is thereforeprevented. Maintaining the integrity of third wall 16 and seventh 20 isessential to ensure the most economical packing and transport of themultiple pallets with pallet containers.

In the second preferred embodiment, as shown in FIGS. 14-20, thecontainer 10 is constructed from blank 200. The second embodimentprovides for a container 10 with a locking mechanism for first leg flap34 and second leg flap 36. Blank 200 is identical to blank 100(described above) except for differences in first bottom flap 30, secondbottom flap 32, inside flaps 90, inside flaps 98, and glue flap 94.Whereas in the first embodiment inside flaps 90 are joined along theirlength to first bottom flap 30, in the second embodiment the insideflaps 90 are notched, thus creating notches 202 between the inside flaps90 and the first bottom flap 30. The bottom side (free end) of firstbottom flap 30 is also double notched, thus creating notches 204 oneither side of glue flap 94. Because of the notches 204, the glue flap94 in this embodiment is preferably only approximately half the lengthof the free end of the first bottom flap 30.

The inside flaps 98 joined to the second bottom flap 32 are alsonotched, thus creating notches 206 between the inside flaps 98 and thesecond bottom flap 32. The bottom side of second bottom flap 32 is alsodouble notched, thus creating notches 208.

As shown in FIGS. 16-20, when the first bottom flap 30 and the secondbottom flap 32 are glued together to form bottom piece 28, two bottomslots 210 are formed in the bottom piece 28 which receive the free endof first leg flap 34 and second leg flap 36. Each slot is formed byabutting one notch 204 and one notch 208. The free end of first leg flap34 and the second leg flap 36 are bent upwardly and tucked into theinterior of the container 10 through the two slots 210.

Once the bottom piece 28 is formed, the inside flaps 90, 98 are bentupward along score lines 88, 96 and abut first wall 12 and fifth wall 18in the interior of the container 10. One notch 204 and one notch 206abut one another in the interior of the container and form slots 212.Once the free ends of first leg flap 34 and second leg flap 36 arereceived through slots 210 in the bottom piece 28, the free ends arefolded parallel to the interior surface of the bottom piece 28 and arereceived and secured by slots 212.

In the third preferred embodiment, as shown in FIGS. 21-30, thecontainer is constructed from blank 300. Blank 300 is comprised of firstrow 38 and second row 40. First row 38 is comprised of a glue flap 58,first wall 12, second wall 14, third wall 16, fourth wall 18, fifth wall20, and glue flap 302. The glue flap 58, first wall 12, second wall 14,third wall 16, fourth wall 18, fifth wall 20, and glue flap 302 arepreferably rectangular in shape. The glue flap 58 is joined to the firstwall 12 via a score line 42. Similarly, the first wall 12 is joined tothe second wall 14 via score line 44, the second wall 14 to the thirdwall 16 via score line 46, the third wall 16 to the fourth wall 18 viascore line 48, the fourth wall 18 to the fifth wall 20 via score line50, and the fifth wall to glue flap 302 along score line 310. Unlike theembodiments previously described, fifth wall 20 is joined to a glue flap302 along score line 310. The first row 38 is joined to the second row40 along score line 78.

The second row 40 of blank 300 is comprised of glue flap 60, inside fold62, a first leg flap 34, inside fold 64, outside fold 66, first bottomflap 30, outside fold 68, inside fold 70, second leg flap 36, insidefold 72, and a glue flap 304. The glue flap 60 is joined to the insidefold 62 along score line 42. First leg flap 34 is joined to inside fold62 along score line 80 on one side and joined to inside fold 64 alongscore line 82 on the other side. Inside fold 64 is joined to outsidefold 66 along score line 44. First bottom flap 30 abuts, but is notjoined to, the outside fold 66 on one side and the outside fold 68 onthe other side. The outside fold 68 is joined to the inside fold 70along score line 50. The second leg flap 36 is joined to inside fold 70along score line 84 on one side and to inside fold 72 along score line86 on the other side. Glue flap 304 is joined to inside fold 72 alongscore line 310.

The first bottom flap 30 is joined to the second bottom flap 32 alongscore line 306, thus forming bottom piece 28. The first bottom flap 30and second bottom flap 32 are preferably in the shape of a pentagon. Thefirst bottom flap 30 and second bottom flap 32 are joined along theirlongest sides. The third wall 16 is joined to the first bottom flap 30at its opposite end along score line 78, while the seventh wall 24 isjoined to second bottom flap 32 at its opposite end along score line308. Joined to the two parallel sides of the first bottom flap 30 viascore lines 88 are inside flaps 90. Joined to the two parallel sides ofthe second bottom flap 32 via score lines 96 are inside flaps 98. Sixthwall 22 is joined to seventh wall 24 on one of its sides along scoreline 54. Seventh wall 24 is joined to eighth wall 26 on one of itsopposite side along score line 56.

As shown in FIGS. 22-30, to construct the pallet container 10 from blank300, the first row 38 is folded along score line 78 forming a 90 degreeangle with first bottom flap 30. The glue flap 58, first wall 12, secondwall 14, third wall 16, fourth wall 18, fifth wall 20, and glue flap 302are bent inward along score lines 42, 44, 46, 48, 50, and 310.Similarly, the sixth wall 22, seventh wall 24, and eighth wall 26 arefolded along score line 308 forming a 90 degree angle with second bottomflap 32. The sixth wall 22, seventh wall 24, and eight wall 26 are benttowards the first row 38 along score lines 54, 56. To create the opening122 of the container 10, glue flap 302 is attached lengthwise to sixthwall 22, glue flap 304 is attached to outside fold 74, glue flap 58 isattached to eighth wall 26, and glue flap 60 is attached to outside fold76. The bottom piece 28 of the container 10 is capable of folding inwardalong score line 306. Thus in the flat position, the first bottom flap30 is folded between third wall 16 and second bottom flap 32, while thesecond bottom flap 32 is folded between first bottom flap 30 and seventhwall 24.

The deployment and collapsing process of the container 10 constructedfrom blank 300 is the same as previously described.

In the fourth preferred embodiment, as shown in FIGS. 31-38, thecontainer 10 is constructed from blank 400 and blank 420. Blank 400 hasa first row 38 and a second row 40. The first row 38 is comprised of aglue flap 58, a first wall 12, a second wall 14, a third wall 16, afourth wall 18, a fifth wall 20, a sixth wall 22, a seventh wall 24, andan eighth wall 26. The glue flap 58, first wall 12, second wall 14,third wall 16, fourth wall 18, fifth wall 20, sixth wall 22, seventhwall 24, and eighth wall 26 are all preferably rectangular in shape. Theglue flap 58 is joined to the first wall 12 via a score line 42.Similarly, the first wall 12 is joined to the second wall 14 via scoreline 44, the second wall 14 to the third wall 16 via score line 46, thethird wall 16 to the fourth wall 18 via score line 48, the fourth wall18 to the fifth wall 20 via score line 50, the fifth wall 20 to thesixth wall 22 via score line 52, the sixth wall 22 to the seventh wall24 via score line 54, and the seventh wall 24 to the eighth wall 26 viascore line 56.

The first row 38 is joined to the second row 40 along score line 78. Thesecond row 40 of blank 400 is comprised of a glue flap 60, an insidefold 62, a first leg flap 34, an inside fold 64, an outside fold 66, afirst bottom glue flap 402, an outside fold 68, an inside fold 70, asecond leg flap 36, an inside fold 72, an outside fold 74, a secondbottom glue flap 404, and an outside fold 76.

The glue flap 60 is joined to the inside fold 62 along score line 42.First leg flap 34 is joined to inside fold 62 along score line 80 on oneside and joined to inside fold 64 along score line 82 on the other side.Inside fold 64 is joined to outside fold 66 along score line 44. Firstbottom glue flap 402 abuts, but is not joined to, the outside fold 66 onone side and the outside fold 68 on the other side. The outside fold 68is joined to the inside fold 70 along score line 50. The second leg flap36 is joined to inside fold 70 along score line 84 on one side and toinside fold 72 along score line 86 on the other side. Inside fold 72 isjoined to outside fold 74 along score line 52. Second bottom glue flap404 abuts, but is not joined to, the outside fold 74 on one side and theoutside fold 76 on the other side. The inside folds 62, 64, 70, 72 aretriangular-shaped, preferably in the shape of a right triangle.

The first bottom glue flap 402 and second bottom glue flap 404 arepreferably in the shape of an isosceles trapezoid (i.e. trapezoid withtwo non-parallel sides the same length). The top side of the glue flaps402, 404 is along score line 78. The bottom side (free end) of the flaps402, 404 is parallel to the top side.

Blank 420 is comprised of a first bottom section 406 and a second bottomsection 408. The bottom sections 406, 408 are preferably in the shape ofpentagon and are joined to one another along score line 418. Joined tothe two parallel sides of the first bottom section 406 via score lines412 are inside flaps 410. Joined to the two parallel sides of the secondbottom section 408 via score lines 416 are inside flaps 414.

As shown in FIGS. 31-38, to form the container 10, blank 420 is attachedto blank 400. Second blank 420 forms the bottom piece 28 of thecontainer 10. First bottom section 406 is preferably glued to the bottomsurface of first bottom glue flap 402, while second bottom section 408is preferably glued to the bottom surface of second bottom glue flap404. To construct the top piece of pallet container 10 from the blank400 of the fourth embodiment, the eight walls are folded inward alongthe score lines 42, 44, 46, 48, 50, 52, 54, 56 of the first row 38. Glueflap 58 is attached to eighth wall 26 to form the octagon opening 122 ofthe container 10. Glue flap 58 is preferably glued to the exteriorsurface of the eighth wall. Glue flap 60 of the second row 40 of theblank 100 is similarly attached to the outside fold 76. When glue flaps58, 60 are attached to the eighth wall 26, score line 42 is aligned withside edge of the eighth wall 26.

When the container is the open position, the inside flaps 410, 414 arebent upward along score lines 412, 416 and abut first wall 12 and fifthwall 18 in the interior of the container 10. The inside flaps 410, 414serve to seal the interior of the container 10.

The deployment and collapsing process of the container 10 constructedfrom blanks 400, 420 is the same as previously described.

In the fifth preferred embodiment, as shown in FIGS. 39-41, thecontainer 10 is constructed from blank 500 and blank 420. Blank 500 hasa first row 38 and a second row 40. The first row 38 is comprised of aglue flap 58, a first wall 12, a second wall 14, a third wall 16, afourth wall 18, a fifth wall 20, a sixth wall 22, a seventh wall 24, andan eighth wall 26. The glue flap 58, first wall 12, second wall 14,third wall 16, fourth wall 18, fifth wall 20, sixth wall 22, seventhwall 24, and eighth wall 26 are all preferably rectangular in shape. Theglue flap 58 is joined to the first wall 12 via a score line 42.Similarly, the first wall 12 is joined to the second wall 14 via scoreline 44, the second wall 14 to the third wall 16 via score line 46, thethird wall 16 to the fourth wall 18 via score line 48, the fourth wall18 to the fifth wall 20 via score line 50, the fifth wall 20 to thesixth wall 22 via score line 52, the sixth wall 22 to the seventh wall24 via score line 54, and the seventh wall 24 to the eighth wall 26 viascore line 56.

The first row 38 is joined to the second row 40 along score line 78. Thesecond row 40 of blank 500 is comprised of a glue flap 60, an insidefold 62, a first leg flap 34, an inside fold 64, an outside fold 66, afirst bottom glue flap 502, an outside fold 68, an inside fold 70, asecond leg flap 36, an inside fold 72, an outside fold 74, a secondbottom glue flap 504, and an outside fold 76. Unlike previouslydescribed embodiments, the first leg flap 34 and second leg flap 36 donot have a free end.

The glue flap 60 is joined to the inside fold 62 along score line 42.First leg flap 34 is joined to inside fold 62 along score line 80 on oneside and joined to inside fold 64 along score line 82 on the other side.Inside fold 64 is joined to outside fold 66 along score line 44. Theoutside fold 68 is joined to the inside fold 70 along score line 50. Thesecond leg flap 36 is joined to inside fold 70 along score line 84 onone side and to inside fold 72 along score line 86 on the other side.Inside fold 72 is joined to outside fold 74 along score line 52. Theinside folds 62, 64, 70, 72 are triangular-shaped, preferably in theshape of a right triangle.

The first bottom glue flap 502 and second bottom glue flap 504 arepreferably in the shape of a rectangle. Thus, first flap 502 does notabut outside fold 66 or outside fold 68. Likewise, second flap 504 doesnot abut outside fold 74 or outside fold 76. The top side of the flaps502, 504 is along score line 78. The bottom side (free end) of the flaps502, 504 is parallel to the top side.

Blank 420 is comprised of a first bottom section 406 and a second bottomsection 408. The bottom sections 406, 408 are preferably in the shape ofpentagon and are joined to one another along score line 418. Joined tothe two parallel sides of the first bottom section 406 via score lines412 are inside flaps 410. Joined to the two parallel sides of the secondbottom flap 408 via score lines 416 are inside flaps 414.

As shown in FIGS. 39-41, to form the container 10, blank 420 is attachedto blank 500. Second blank 420 forms the bottom piece 28 of thecontainer 10. First bottom section 406 is preferably glued to the bottomsurface of first bottom glue flap 502, while second bottom section 408is preferably glued to the bottom surface of second bottom glue flap504. To construct the top piece of pallet container 10 from the blank500 of the fifth embodiment, the eight walls are folded inward along thescore lines 42, 44, 46, 48, 50, 52, 54, 56 of the first row 38. Glueflap 58 is attached to eighth wall 26 to form the octagon opening 122 ofthe container 10. Glue flap 58 is preferably glued to the exteriorsurface of the eighth wall. Glue flap 60 of the second row 40 of theblank 500 is similarly attached to the outside fold 76. When glue flaps58, 60 are attached to the eighth wall 26, score line 42 is aligned withside edge of the eighth wall 26.

When the container is the open position, the inside flaps 410, 414 arebent upward along score lines 412, 416 and abut first wall 12 and fifthwall 18 in the interior of the container 10. The inside flaps 410, 414serve to seal the interior of the container 10.

The deployment and collapsing process of the container 10 constructedfrom blanks 500, 420 is the same as previously described.

In the sixth preferred embodiment, as shown in FIGS. 42-44, thecontainer 10 is constructed from blank 600, blank 602 and blank 420.Blank 600 has a first row 38 and a second row 40. The first row 38 iscomprised of a glue flap 58, a first wall 12, a second wall 14, a thirdwall 16, and a fourth wall 18. The glue flap 58, first wall 12, secondwall 14, third wall 16, and fourth wall 18 are all preferablyrectangular in shape. The glue flap 58 is joined to the first wall 12via a score line 42. Similarly, the first wall 12 is joined to thesecond wall 14 via score line 44, the second wall 14 to the third wall16 via score line 46, and the third wall 16 to the fourth wall 18 viascore line 48.

Blank 602 has a first row 606 and a second row 608. The first row 606 iscomprised of glue flap 604, a fifth wall 20, a sixth wall 22, a seventhwall 24, and an eighth wall 26. Glue flap 604, fifth wall 20, sixth wall22, seventh wall 24, and eighth wall 26 are all preferably rectangularin shape. The glue flap is preferably joined to the fifth wall 20 viascore line 50, the fifth wall 20 to the sixth wall 22 via score line 52,the sixth wall 22 to the seventh wall 24 via score line 54, and theseventh wall 24 to the eighth wall 26 via score line 56.

The first row 38 of blank 600 is joined to the second row 40 along scoreline 78. The second row 40 of blank 600 is comprised of a glue flap 60,an inside fold 62, a first leg flap 34, an inside fold 64, an outsidefold 66, a first bottom glue flap 502, and an outside fold 68. The firstrow 606 of blank 602 is joined to the second row 608 along score line78. The second row of blank 602 is comprised of glue flap 610, an insidefold 70, a second leg flap 36, an inside fold 72, an outside fold 74, asecond bottom glue flap 504, and an outside fold 76.

Glue flap 60 is joined to the inside fold 62 along score line 42. Firstleg flap 34 is joined to inside fold 62 along score line 80 on one sideand joined to inside fold 64 along score line 82 on the other side.Inside fold 64 is joined to outside fold 66 along score line 44. Glueflap 610 is joined to the inside fold 70 along score line 50. The secondleg flap 36 is joined to inside fold 70 along score line 84 on one sideand to inside fold 72 along score line 86 on the other side. Inside fold72 is joined to outside fold 74 along score line 52. The inside folds62, 64, 70, 72 are triangular-shaped, preferably in the shape of a righttriangle.

The first bottom glue flap 502 and second bottom glue flap 504 arepreferably in the shape of a rectangle. Thus, first flap 502 does notabut outside fold 66 or outside fold 68. Likewise, second flap 504 doesnot abut outside fold 74 or outside fold 76. The top side of the flaps502, 504 is along score line 78. The bottom side of the flaps 502, 504is parallel to the top side.

Blank 420 is comprised of a first bottom section 406 and a second bottomsection 408. The bottom sections 406, 408 are preferably in the shape ofpentagon and are joined to one another along score line 418. Joined tothe two parallel sides of the first bottom section 406 via score lines412 are inside flaps 410. Joined to the two parallel sides of the secondbottom flap 408 via score lines 416 are inside flaps 414.

As shown in FIGS. 42-44, to construct the top piece of pallet container10 from the blank 600 and blank 602, the glue flap 604 is attached tofourth wall 18 and glue flap 601 is attached to outside fold 68. Blank420 is attached to the attached blanks 600, 602. Second blank 420 formsthe bottom piece 28 of the container 10. First bottom section 406 ispreferably glued to the bottom surface of first bottom glue flap 502,while second bottom section 408 is preferably glued to the bottomsurface of second bottom glue flap 504.

The eight walls are folded inward along the score lines 42, 44, 46, 48,50, 52, 54, 56 of the first row 38. Glue flap 58 is attached to eighthwall 26 to form the octagon opening 122 of the container 10. Glue flap58 is preferably glued to the exterior surface of the eighth wall. Glueflap 60 of the second row 40 of the blank 600 is similarly attached tothe outside fold 76. When glue flaps 58, 60 are attached to the eighthwall 26, score line 42 is aligned with side edge of the eighth wall 26.

When the container is the open position, the inside flaps 410, 414 arebent upward along score lines 412, 416 and abut first wall 12 and fifthwall 18 in the interior of the container 10. The inside flaps 410, 414serve to seal the interior of the container 10.

The deployment and collapsing process of the container 10 constructedfrom blanks 600, 602, 420 is the same as previously described.

In the seventh preferred embodiment, as shown in FIGS. 45-57, thecontainer 10 is constructed from blank 700 and blank 702. Blank 700 andblank 702 are preferably complementary. Blank 700 has a first row 38 anda second row 40. The first row 38 is comprised of a glue flap 58, afirst wall 12, a second wall 14, a third wall 16, and a fourth wall 18.The glue flap 58, first wall 12, second wall 14, third wall 16, andfourth wall 18 are all preferably rectangular in shape. The glue flap 58is joined to the first wall 12 via a score line 42. Similarly, the firstwall 12 is joined to the second wall 14 via score line 44, the secondwall 14 to the third wall 16 via score line 46, and the third wall 16 tothe fourth wall 18 via score line 48.

Blank 702 has a first row 712 and a second row 714. The first row 712 iscomprised of glue flap 704, a fifth wall 20, a sixth wall 22, a seventhwall 24, and an eighth wall 26. Glue flap 704, fifth wall 20, sixth wall22, seventh wall 24, and eighth wall 26 are all preferably rectangularin shape. The glue flap is preferably joined to the fifth wall 20 viascore line 50, the fifth wall 20 to the sixth wall 22 via score line 52,the sixth wall 22 to the seventh wall 24 via score line 54, and theseventh wall 24 to the eighth wall 26 via score line 56.

The first row 38 of blank 700 is joined to the second row 40 along scoreline 78. The second row 40 of blank 700 is comprised of a glue flap 60,an inside fold 62, a first leg flap 34, an inside fold 64, an outsidefold 66, a first bottom flap 30, and an outside fold 68. The first row712 of blank 702 is joined to the second row 608 along score line 716.The second row of blank 602 is comprised of glue flap 706, an insidefold 70, a second leg flap 36, an inside fold 72, an outside fold 74, asecond bottom flap 32, and an outside fold 76.

The glue flap 60 of blank 700 is joined to the inside fold 62 alongscore line 42. First leg flap 34 is joined to inside fold 62 along scoreline 80 on one side and joined to inside fold 64 along score line 82 onthe other side. Inside fold 64 is joined to outside fold 66 along scoreline 44. First bottom flap 30 abuts, but is not joined to, the outsidefold 66 on one side and the outside fold 68 on the other side. The glueflap 706 of blank 702 is joined to the inside fold 70 along score line50. The second leg flap 36 is joined to inside fold 70 along score line84 on one side and to inside fold 72 along score line 86 on the otherside. Inside fold 72 is joined to outside fold 74 along score line 52.Second bottom flap 32 abuts, but is not joined to, the outside fold 74on one side and the outside fold 76 on the other side. The inside folds62, 64, 70, 72 are triangular-shaped, preferably in the shape of a righttriangle.

The first bottom flap 30 and second bottom flap 32 are preferably in theshape of pentagon. The top side of the flaps 30, 32 is along score line78. The bottom side (free end) of the flaps 30, 32 is parallel to thetop side. Joined to the two parallel sides of the first bottom flap 30via score lines 88 are inside flaps 90. Joined to the two parallel sidesof the second bottom flap 32 via score lines 96 are inside flaps 98.Joined to the bottom side of flap 30 is glue flap 708. Glue flap 708extends approximately one-half of the length of the bottom side. Glueflap 710 is joined to the bottom side of flap 32. Glue Flap 710 extendsapproximately one-half of the length of the bottom side.

As shown in FIGS. 46-53, to construct the pallet container 10 fromblanks 700, 702, glue flap 708 is attached to first bottom flap 30 andglue flap 710 is attached to second bottom flap 32. To construct the toppiece of the container 10, glue flap 58 of blank 700 is attached toeighth wall 26 of blank 702. Glue flap 60 is also attached to outsidefold 76. In addition, glue flap 704 of blank 702 is attached to fourthwall 18. Glue flap 706 is also attached to outside fold 68. Once theeight walls are folded inward along the score lines 42, 44, 46, 48, 50,52, 54, 56, the octagon 122 opening of the container 10 is formed.

The deployment and collapsing process of the container 10 constructedfrom blanks 700, 702 is the same as previously described.

In eighth preferred embodiment, as shown in FIGS. 58-69, the container10 is constructed from blank 800. The blank 800 has a first row 38 and asecond row 40. The first row 38 is comprised of a glue flap 58, a firstwall 12, a second wall 14, a third wall 16, a fourth wall 18, a fifthwall 20, a sixth wall 22, a seventh wall 24, and an eighth wall 26. Theglue flap 58, first wall 12, second wall 14, third wall 16, fourth wall18, fifth wall 20, sixth wall 22, seventh wall 24, and eighth wall 26are all preferably rectangular in shape. The glue flap 58 is joined tothe first wall 12 via a score line 42. Similarly, the first wall 12 isjoined to the second wall 14 via score line 44, the second wall 14 tothe third wall 16 via score line 46, the third wall 16 to the fourthwall 18 via score line 48, the fourth wall 18 to the fifth wall 20 viascore line 50, the fifth wall 20 to the sixth wall 22 via score line 52,the sixth wall 22 to the seventh wall 24 via score line 54, and theseventh wall 24 to the eighth wall 26 via score line 56. In one versionof this embodiment, first wall 12 and first leg flap 34 are bisected byscore line 118. In another version, depending on the intended use of thecontainer 10, score line 118 is absent. Similarly, fifth wall 20 andsecond leg flap 36 may or may not be bisected by score line 120.

The first row 38 is joined to the second row 40 along score line 78. Thesecond row 40 of blank 800 is comprised of a glue flap 60, an insidefold 62, a first leg flap 34, an inside fold 64, an outside fold 66, afirst bottom flap 802, an outside fold 68, an inside fold 70, a secondleg flap 36, an inside fold 72, an outside fold 74, a second bottom flap808, and an outside fold 76.

The glue flap 60 is joined to the inside fold 62 along score line 42.First leg flap 34 is joined to inside fold 62 along score line 80 on oneside and joined to inside fold 64 along score line 82 on the other side.Inside fold 64 is joined to outside fold 66 along score line 44. Firstbottom flap 802 abuts, but is not joined to, the outside fold 66 on oneside and the outside fold 68 on the other side. The outside fold 68 isjoined to the inside fold 70 along score line 50. The second leg flap 36is joined to inside fold 70 along score line 84 on one side and toinside fold 72 along score line 86 on the other side. Inside fold 72 isjoined to outside fold 74 along score line 52. Second bottom flap 808abuts, but is not joined to, the outside fold 74 on one side and theoutside fold 76 on the other side. Inside folds 62, 64, 70, 72 aretriangular-shaped, preferably in the shape of a right triangle.

The top sides of first bottom flap 802 and second bottom flap 808 arealong score line 78. The bottom side (free end) of the flap 802 consistsof a notch 812 which creates a locking tab 810. The free end of flap 808consists of a notch 816 which creates a locking tab 814.

To construct the pallet container 10 from the blank 800, the eight wallsare folded inward along the score lines 42, 44, 46, 48, 50, 52, 54, 56of the first row 38. Glue flap 58, which is joined to first wall 12, isattached to eighth wall 26 to form the octagon opening 122 of thecontainer 10. Glue flap 58 is preferably glued to the exterior surfaceof the eighth wall. Glue flap 60 of the second row 40 of the blank 100is similarly attached to the outside fold 76. When glue flaps 58, 60 areattached to the eighth wall 26, score line 42 is aligned with side edgeof the eighth wall 26.

As shown in FIG. 68, the bottom piece 28 of the container is formed byinterlocking the first bottom flap 802 and the second bottom flap 808.The flaps 802, 808 are interlocked by hooking locking tab 810 into notch816 and hooking locking tab 814 into notch 812. This causes locking tab810 to rest on the top surface of second bottom flap 808 and locking tab814 to rest on the top surface of first bottom flap 802.

In the version of this embodiment comprising score line 118 and scoreline 120, the first step of the deployment of the container 10constructed from blank 800 is the same as previously described. However,in the absence of score line 118 and score line 120, the configurationof the container 10 constructed from blank 800 in the flat position isdifferent from the previously described embodiments. Specifically, thecontainer 10 is folded along score line 44 and score line 52 when in theflat position, instead of score lines 118, 120.

In the top opening step of the deployment process of the container, theuser pushes score line 44 and score line 52 towards each other. Thisaction transitions the container 10 into the open position. An opening122 in the top end of the container 10 is created by the eight joinedwalls 12, 14, 16, 18, 20, 22, 24, 26.

The second step of the deployment process is the bottom closing process.Once the top of the container 10 has been opened, the container 10preferably is turned upside down to secure the bottom piece 28 of thecontainer 10 by interlocking the first bottom flap 802 and the secondbottom flap 808. As explained above, the flaps 802, 808 are interlockedby hooking locking tab 810 into notch 816 and hooking locking tab 814into notch 812. This causes locking tab 810 to rest on the top surfaceof second bottom flap 808 and locking tab 814 to rest on the top surfaceof first bottom flap 802.

Once the bottom piece 28 is assembled, pressure is exerted on the firstleg flap 34 and the second leg flap 36. The pressure can be appliedmanually when the container 10 is upside down or by rocking thecontainer 10 back-and-forth on first leg flap 34 and second leg flap 36when the container 12 is in the upright position. This pressure causesthe leg flaps 34, 36 fold under the bottom piece of the container 10along score line 78. During the folding process of first leg flap 34,outside fold 76 (connected to glue flap 60) is forced to fold on top offirst leg flap 34 along score lines 78, 42, and 80. Thus, inside fold 62is folded between outside fold 76 and first leg flap 34. Similarly,outside fold 66 is forced to fold on top of first leg flap 34 alongscore lines 78, 44, and 82. Thus, inside fold 64 is folded betweenoutside fold 66 and the first leg flap 34. During the folding process ofsecond leg flap 36, outside fold 68 is forced to fold on top of secondleg flap 36 along score lines 78, 50, and 84. Thus, inside fold 70 isfolded between outside fold 68 and second leg flap 36. Similarly,outside fold 74 is forced to fold on top of second leg flap 36 alongscore lines 78, 52, and 86. Thus, inside fold 72 is folded betweenoutside fold 74 and second leg flap 36. In application, the weight ofthe load inside the container 10 holds the first leg flap 34 and thesecond leg flap 36 parallel with bottom piece 28, and thus allows theflaps 34, 36 to serve as reinforcement to the bottom piece 28 of thecontainer.

In ninth preferred embodiment, as shown in FIGS. 70-80, the container 10is constructed from blank 900. The blank 900 has a first row 38 and asecond row 40. The first row 38 is comprised of a glue flap 58, a firstwall 12, a second wall 14, a third wall 16, a fourth wall 18, a fifthwall 20, a sixth wall 22, a seventh wall 24, and an eighth wall 26. Theglue flap 58, first wall 12, second wall 14, third wall 16, fourth wall18, fifth wall 20, sixth wall 22, seventh wall 24, and eighth wall 26are all preferably rectangular in shape. The glue flap 58 is joined tothe first wall 12 via a score line 42. Similarly, the first wall 12 isjoined to the second wall 14 via score line 44, the second wall 14 tothe third wall 16 via score line 46, the third wall 16 to the fourthwall 18 via score line 48, the fourth wall 18 to the fifth wall 20 viascore line 50, the fifth wall 20 to the sixth wall 22 via score line 52,the sixth wall 22 to the seventh wall 24 via score line 54, and theseventh wall 24 to the eighth wall 26 via score line 56.

The first row 38 is joined to the second row 40 along score line 78. Thesecond row 40 of blank 900 is comprised of a glue flap 60, an insidefold 62, a first leg flap 902, an inside fold 64, an outside fold 66, afirst bottom flap 802, an outside fold 68, an inside fold 70, a secondleg flap 904, an inside fold 72, an outside fold 74, a second bottomflap 808, and an outside fold 76.

The glue flap 60 is joined to the inside fold 62 along score line 42.First leg flap 902 is joined to inside fold 62 along score line 80 onone side and joined to inside fold 64 along score line 82 on the otherside. Inside fold 64 is joined to outside fold 66 along score line 44.First bottom flap 804 abuts, but is not joined to, the outside fold 66on one side and the outside fold 68 on the other side. The outside fold68 is joined to the inside fold 70 along score line 50. The second legflap 904 is joined to inside fold 70 along score line 84 on one side andto inside fold 72 along score line 86 on the other side. Inside fold 72is joined to outside fold 74 along score line 52. Second bottom flap 808abuts, but is not joined to, the outside fold 74 on one side and theoutside fold 76 on the other side. Inside folds 62, 64, 70, 72 aretriangular-shaped, preferably in the shape of a right triangle.

The top sides of first bottom flap 802 and second bottom flap 808 arealong score line 78. The bottom side (free end) of the flap 802 consistsof a notch 812 which creates a locking tab 810. The free end of flap 808consists of a notch 816 which creates a locking tab 814. The surface ofthe first bottom flap 802 also has an opening 906, preferably in theshape of an oval, shaped to receive the free end of first leg flap 902.The surface of the second bottom also has an opening 908, preferably inthe shape of an oval, shaped to receive the free end of second leg flap904.

To construct the pallet container 10 from the blank 900, the eight wallsare folded inward along the score lines 42, 44, 46, 48, 50, 52, 54, 56of the first row 38. Glue flap 58, which is joined to first wall 12, isattached to eighth wall 26 to form the octagon opening 122 of thecontainer 10. Glue flap 58 is preferably glued to the exterior surfaceof the eighth wall. Glue flap 60 of the second row 40 of the blank 100is similarly attached to the outside fold 76. When glue flaps 58, 60 areattached to the eighth wall 26, score line 42 is aligned with side edgeof the eighth wall 26.

The bottom piece 28 of the container is formed by interlocking the firstbottom flap 802 and the second bottom flap 808. The flaps 802, 808 areinterlocked by hooking locking tab 810 into notch 816 and hookinglocking tab 814 into notch 812. This causes locking tab 810 to rest onthe top surface of second bottom flap 808 and locking tab 814 to rest onthe top surface of first bottom flap 802.

As shown in FIG. 79, to further secure the bottom piece 28 of thecontainer 10, the free end portion of first leg flap 902 is receivedthrough hole 906 in first bottom flap 802 and the free end portion ofsecond leg flap 904 is received through hole 908 in second bottom flap808. Once the free ends of the leg flaps 1002, 1004 are received by theholes 1006, 1008, the free ends are folded parallel to the interiorsurface of the bottom piece 28 to lock them into place.

With the absence of score line 118 and score line 120, the configurationof the container 10 constructed from blank 900 in the flat position isdifferent from the first seven previously described embodiments.Specifically, the container 10 is folded along score line 44 and scoreline 52 when in the flat position.

In the top opening step of the deployment process of the container, theuser pushes score line 44 and score line 52 towards each other. Thisaction transitions the container 10 into the open position. An opening122 in the top end of the container 10 is created by the eight joinedwalls 12, 14, 16, 18, 20, 22, 24, 26.

The second step of the deployment process is the bottom closing process.Once the top of the container 10 has been opened, the container 10preferably is turned upside down to secure the bottom piece 28 of thecontainer 10 by interlocking the first bottom flap 802 and the secondbottom flap 808. As explained above, the flaps 802, 808 are interlockedby hooking locking tab 810 into notch 816 and hooking locking tab 814into notch 812. This causes locking tab 810 to rest on the top surfaceof second bottom flap 808 and locking tab 814 to rest on the top surfaceof first bottom flap 802. To further secure the bottom piece of thecontainer 10, the free end portion of first leg flap 1002 is receivedthrough hole 1006 in first bottom flap 802 and the free end portion ofsecond leg flap 1004 is received through hole 1008 in second bottom flap808. Once the free ends of the leg flaps 1002, 1004 are received by theholes 1006, 1008, the free ends are folded parallel to the interiorsurface of the bottom piece 28 to lock them into place.

Once the bottom piece 28 is assembled, pressure is exerted on the firstleg flap 34 and the second leg flap 36. The pressure can be appliedmanually when the container 10 is upside down or by rocking thecontainer 10 back-and-forth on first leg flap 34 and second leg flap 36when the container 12 is in the upright position. This pressure causesthe leg flaps 34, 36 fold under the bottom piece of the container 10along score line 78. During the folding process of first leg flap 34,outside fold 76 (connected to glue flap 60) is forced to fold on top offirst leg flap 34 along score lines 78, 42, and 80. Thus, inside fold 62is folded between outside fold 76 and first leg flap 34. Similarly,outside fold 66 is forced to fold on top of first leg flap 34 alongscore lines 78, 44, and 82. Thus, inside fold 64 is folded betweenoutside fold 66 and the first leg flap 34. During the folding process ofsecond leg flap 36, outside fold 68 is forced to fold on top of secondleg flap 36 along score lines 78, 50, and 84. Thus, inside fold 70 isfolded between outside fold 68 and second leg flap 36. Similarly,outside fold 74 is forced to fold on top of second leg flap 36 alongscore lines 78, 52, and 86. Thus, inside fold 72 is folded betweenoutside fold 74 and second leg flap 36. In application, the weight ofthe load inside the container 10 holds the first leg flap 34 and thesecond leg flap 36 parallel with bottom piece 28, and thus allows theflaps 34, 36 to serve as reinforcement to the bottom piece 28 of thecontainer.

In tenth preferred embodiment, as shown in FIGS. 81-92, the container 10is constructed from blank 1000. The blank 1000 has a first row 38 and asecond row 40. The first row 38 is comprised of a glue flap 58, a firstwall 12, a second wall 14, a third wall 16, a fourth wall 18, a fifthwall 20, a sixth wall 22, a seventh wall 24, and an eighth wall 26. Theglue flap 58, first wall 12, second wall 14, third wall 16, fourth wall18, fifth wall 20, sixth wall 22, seventh wall 24, and eighth wall 26are all preferably rectangular in shape. The glue flap 58 is joined tothe first wall 12 via a score line 42. Similarly, the first wall 12 isjoined to the second wall 14 via score line 44, the second wall 14 tothe third wall 16 via score line 46, the third wall 16 to the fourthwall 18 via score line 48, the fourth wall 18 to the fifth wall 20 viascore line 50, the fifth wall 20 to the sixth wall 22 via score line 52,the sixth wall 22 to the seventh wall 24 via score line 54, and theseventh wall 24 to the eighth wall 26 via score line 56.

Top flaps are joined to each side wall. Flap 1002 is joined to firstwall 12, flap 1004 is joined to second wall 14, flap 1006 is joined tothird wall 16, flap 1008 is joined to fourth wall 18, flap 1010 isjoined to fifth wall 20, flap 1012 is joined to sixth wall 22, flap 1014is joined to seventh wall 24, and flap 1016 is joined to eighth wall 26.

As shown in FIG. 81, cut into first wall 12 is flap 1034 which ispreferably square or rectangular in shape. The flap 1034 is preferablycut along the bottom side and left and right sides of the flap 1034,leaving only the top side of the flap 1034 attached to first panel 12.Similarly, flap 1036 is cut into fifth wall 20 which is preferablysquare or rectangular in shape. The flap 1034 is preferably cut alongthe bottom side and left and right sides of the flap 1036, leaving onlythe top side of the flap 1034 attached to the fifth panel 20.

The first row 38 is joined to the second row 40 along score line 78. Thesecond row 40 of blank 1000 is comprised of a glue flap 60, an insidefold 62, a first leg flap 34, an inside fold 64, an outside fold 66, afirst bottom flap 802, an outside fold 68, an inside fold 70, a secondleg flap 36, an inside fold 72, an outside fold 74, a second bottom flap808, and an outside fold 76.

The glue flap 60 is joined to the inside fold 62 along score line 42.First leg flap 34 is joined to inside fold 62 along score line 80 on oneside and joined to inside fold 64 along score line 82 on the other side.Inside fold 64 is joined to outside fold 66 along score line 44. Firstbottom flap 802 abuts, but is not joined to, the outside fold 66 on oneside and the outside fold 68 on the other side. The outside fold 68 isjoined to the inside fold 70 along score line 50. The second leg flap 36is joined to inside fold 70 along score line 84 on one side and toinside fold 72 along score line 86 on the other side. Inside fold 72 isjoined to outside fold 74 along score line 52. Second bottom flap 808abuts, but is not joined to, the outside fold 74 on one side and theoutside fold 76 on the other side. Inside folds 62, 64, 70, 72 aretriangular-shaped, preferably in the shape of a right triangle.

The top sides of first bottom flap 802 and second bottom flap 808 arealong score line 78. The bottom side (free end) of the flap 802 consistsof a notch 812 which creates a locking tab 810. The free end of flap 808consists of a notch 816 which creates a locking tab 814. Attached to oneside of flap 802 along score line 1042 is a locking piece 1038.Similarly, attached to one side of flap 808 along score line 1044 is alocking piece 1040.

To construct the pallet container 10 from the blank 1000, the eightwalls are folded inward along the score lines 42, 44, 46, 48, 50, 52,54, 56 of the first row 38. Glue flap 58, which is joined to first wall12, is attached to eighth wall 26 to form the octagon opening 122 of thecontainer 10. Glue flap 58 is preferably glued to the exterior surfaceof the eighth wall. Glue flap 60 of the second row 40 of the blank 100is similarly attached to the outside fold 76. When glue flaps 58, 60 areattached to the eighth wall 26, score line 42 is aligned with side edgeof the eighth wall 26.

The bottom piece 28 of the container is formed by interlocking the firstbottom flap 802 and the second bottom flap 808. The flaps 802, 808 areinterlocked by hooking locking tab 810 into notch 816 and hookinglocking tab 814 into notch 812. This causes locking tab 810 to rest onthe top surface of second bottom flap 808 and locking tab 814 to rest onthe top surface of first bottom flap 802.

In the top opening step of the deployment process of the container, theuser pushes score line 44 and score line 52 towards each other. Thisaction transitions the container 10 into the open position. An opening122 in the top end of the container 10 is created by the eight joinedwalls 12, 14, 16, 18, 20, 22, 24, 26.

The second step of the deployment process is the bottom closing process.Once the top of the container 10 has been opened, the container 10preferably is turned upside down to secure the bottom piece 28 of thecontainer 10 by interlocking the first bottom flap 802 and the secondbottom flap 808. As explained above, the flaps 802, 808 are interlockedby hooking locking tab 810 into notch 816 and hooking locking tab 814into notch 812. This causes locking tab 810 to rest on the top surfaceof second bottom flap 808 and locking tab 814 to rest on the top surfaceof first bottom flap 802. As shown in FIGS. 86-88, to further secure thebottom piece 28, locking piece 1038 is received by flap 1034.

Locking piece 1038 is then folded downward along score line 1042 therebylocking first bottom flap 802 to first wall 12. Similarly, locking piece1040 is received by flap 1036. Locking piece 1040 is then foldeddownward along score line 1044 thereby locking second bottom flap 808 tofifth wall 20.

Once the bottom piece 28 is assembled, pressure is exerted on the firstleg flap 34 and the second leg flap 36. The pressure can be appliedmanually when the container 10 is upside down or by rocking thecontainer 10 back-and-forth on first leg flap 34 and second leg flap 36when the container 12 is in the upright position. This pressure causesthe leg flaps 34, 36 fold under the bottom piece of the container 10along score line 78. During the folding process of first leg flap 34,outside fold 76 (connected to glue flap 60) is forced to fold on top offirst leg flap 34 along score lines 78, 42, and 80. Thus, inside fold 62is folded between outside fold 76 and first leg flap 34. Similarly,outside fold 66 is forced to fold on top of first leg flap 34 alongscore lines 78, 44, and 82. Thus, inside fold 64 is folded betweenoutside fold 66 and the first leg flap 34. During the folding process ofsecond leg flap 36, outside fold 68 is forced to fold on top of secondleg flap 36 along score lines 78, 50, and 84. Thus, inside fold 70 isfolded between outside fold 68 and second leg flap 36. Similarly,outside fold 74 is forced to fold on top of second leg flap 36 alongscore lines 78, 52, and 86. Thus, inside fold 72 is folded betweenoutside fold 74 and second leg flap 36. In application, the weight ofthe load inside the container 10 holds the first leg flap 34 and thesecond leg flap 36 parallel with bottom piece 28, and thus allows theflaps 34, 36 to serve as reinforcement to the bottom piece 28 of thecontainer.

As shown in FIG. 81, first wall 12, third wall 16, fifth wall 20, andseventh wall 24 also comprise handles 1026, 1028, 1030, 1032. Thehandles 1026, 1028, 1030, 1032 are preferably oval shaped and may beused to grasp the pallet container 10 to physically remove it from thepallet or otherwise move the pallet container 10 once off the pallet.

First wall 12, third wall 16, fifth wall 20, and seventh wall 24 alsocomprise slots 1018, 1020, 1022, 1024. As shown in FIG. 81, the slots1018, 1020, 1022, 1024 are positioned along the top edge of first wall12, third wall 16, fifth wall 20, and seventh wall 24 and are shaped toreceive the locking tabs 1048, 1050, 1052, 1054 of cap 1046. As shown inFIG. 90, the cap 1046 is preferably in the shape of an octagon. Thelocking tabs 1048, 1050, 1052, 1054 are joined to the first side, thirdside, fifth side and seventh side of the cap 1046. As shown in FIG. 91,the locking tabs 1048, 1050, 1052, 1054 of cap 1046 are received byslots 1018, 1020, 1022, 1024 which allows the cap 1046 to attach to thepallet container 10 and close the opening 122 of the pallet container10. The cap 1046 serves to protect the contents of the pallet container10.

Once the cap 1046 has been inserted into the pallet container 10, flaps1002, 1004, 1006, 1008, 1010, 1012, 1014, 1016 are folded downward alongscore line 1056 as shown in FIG. 92. The angled sides of the flaps 1002,1004, 1006, 1008, 1010, 1012, 1014, 1016 abut one another when foldeddown as shown in FIG. 92. The flaps 1002, 1004, 1006, 1008, 1010, 1012,1014, 1016 can be glued or otherwise joined to one another. When theflaps 1002, 1004, 1006, 1008, 1010, 1012, 1014, 1016 are joined to oneanother, they form a rim 1058 around the top of the pallet container 10.The rim 1058 further secures the cap 1046 into place.

In the eleventh preferred embodiment, as shown in FIGS. 93-99, thecontainer 10 is constructed from blank 1100 and blank 1102. Blank 1100has a first row 38 and a second row 40. The first row 38 is comprised ofa glue flap 58, a first wall 12, a second wall 14, a third wall 16, anda fourth wall 18. The glue flap 58, first wall 12, second wall 14, thirdwall 16, and fourth wall 18 are all preferably rectangular in shape. Theglue flap 58 is joined to the first wall 12 via a score line 42.Similarly, the first wall 12 is joined to the second wall 14 via scoreline 44, the second wall 14 to the third wall 16 via score line 46, andthe third wall 16 to the fourth wall 18 via score line 48.

Blank 1102 has a first row 1142 and a second row 1144. The first row1142 is comprised of glue flap 704, a fifth wall 20, a sixth wall 22, aseventh wall 24, and an eighth wall 26. Glue flap 704, fifth wall 20,sixth wall 22, seventh wall 24, and eighth wall 26 are all preferablyrectangular in shape. The glue flap is preferably joined to the fifthwall 20 via score line 50, the fifth wall 20 to the sixth wall 22 viascore line 52, the sixth wall 22 to the seventh wall 24 via score line54, and the seventh wall 24 to the eighth wall 26 via score line 56.

The first row 38 of blank 1100 is joined to the second row 40 alongscore line 78. The second row 40 of blank 1100 is comprised of a glueflap 60, an inside fold 62, a first leg flap 1104, an inside fold 64, anoutside fold 66, a first bottom flap 1112, and an outside fold 68. Thefirst row 1142 of blank 1102 is joined to the second row 1144 alongscore line 716. The second row of blank 1102 is comprised of glue flap706, an inside fold 70, a second leg flap 1106, an inside fold 72, anoutside fold 74, a second bottom flap 1114, and an outside fold 76.

The glue flap 60 of blank 1100 is joined to the inside fold 62 alongscore line 42. First leg flap 1104 is joined to inside fold 62 alongscore line 80 on one side and joined to inside fold 64 along score line82 on the other side. Inside fold 64 is joined to outside fold 66 alongscore line 44. First bottom flap 1112 abuts, but is not joined to, theoutside fold 66 on one side and the outside fold 68 on the other side.The glue flap 706 of blank 1102 is joined to the inside fold 70 alongscore line 50. The second leg flap 1106 is joined to inside fold 70along score line 84 on one side and to inside fold 72 along score line86 on the other side. Inside fold 72 is joined to outside fold 74 alongscore line 52. Second bottom flap 1114 abuts, but is not joined to, theoutside fold 74 on one side and the outside fold 76 on the other side.The inside folds 62, 64, 70, 72 are triangular-shaped, preferably in theshape of a right triangle.

The first bottom flap 1112 and second bottom flap 1114 are substantiallyin the shape of pentagon. The top side of flap 1112 is along doublescore lines 78, 1124. The top side of flap 1114 is along double scorelines 716, 1126. The bottom side (free end) of the flaps 1112, 1114 isparallel to the top side. Joined to the bottom side of flap 1112 is glueflap 1132. The flap 1112 is separated from glue flap 1132 by two scorelines 1128, 1130. The double score lines are used to prevent thecorrugated material from splitting or fracturing when the blanks arefolded. The top corners of the first bottom flap 1112 include roundedsections 1134, 1136 positioned between the double score lines 78, 1124.Similarly, the top corners of the second bottom flap 1114 includerounded sections 1138, 1140 positioned between the double score lines716, 1126. These rounded sections prevent tearing of the bottom flaps1112, 1114 when the blanks 1100, 1102 are folded along score lines 46,48, 54, 56.

The free end of flap 1104 includes two hooked portions 1108 positionedopposite one another. The free end of flap 1106 includes two hookedportions 1110 positioned opposite one another. The surface of the firstbottom flap 1112 has two openings 1116 shaped to receive one hooked end1108 of flap 1104 and one hooked end 1110 of flap 1106. The surface ofthe second bottom flap 1114 also has two openings 1118 shaped to receiveone hooked end 1108 of flap 1104 and one hooked end 1110 of flap 1106.The bottom flaps 1112, 1114 each also include an oval opening 1120,1122. The openings serve as hand holes for use while assembling thecontainer 10 formed from blanks 1100, 1102.

To construct the pallet container 10 from blanks 1100, 1102, glue flap1132 is attached to second bottom flap 1114. To construct the top pieceof the container 10, glue flap 58 of blank 1100 is attached to eighthwall 26 of blank 1102. Glue flap 60 is also attached to outside fold 76.In addition, glue flap 704 of blank 1102 is attached to fourth wall 18.Glue flap 706 is also attached to outside fold 68. Once the eight wallsare folded inward along the score lines 42, 44, 46, 48, 50, 52, 54, 56,the octagon 122 opening of the container 10 is formed.

The deployment process of the container 10 constructed from blanks 1100,1102 is the same as previously described. Once the container 10 isdeployed, to further secure the bottom piece 28 of the container 10, onehooked end 1108 of first leg flap 1104 is received and secured throughopening 1116 in first bottom flap 1112 and the other hooked end 1108 isreceived and secured through opening 1118 in second bottom flap 1114.One hooked end 1110 of the second leg flap 1106 is received and securedthrough the second opening 1116 in the first bottom flap 1112 and theother hooked end 1110 is received and secured through the second opening1118 in second bottom flap 1114. Using the hooked ends 1108, 1110 tofurther secure the bottom piece 28 of the container 10 is optional. Inother words, the container 10 is fully functional without locking thehooked ends 1108, 1110. The hand holes 1120, 1122 may assist theassembler in locking the hooked ends 1108, 1110 in the receiving slots1116, 1118. To collapse the container 10 formed from blanks 1100, 1102,the hooked ends 1108, 1110 must be removed from the openings 1116, 1118and the container 10 may be collapsed as previously described.

Although illustrative embodiments of the invention have been describedin detail, it is to be understood that the present invention is notlimited to those precise embodiments, and that various changes andmodifications can be effected therein by one skilled in the art withoutdeparting from the scope and spirit of the invention as defined by theclaims.

The present invention has been described with reference to certainpreferred and alternative embodiments that are intended to be exemplaryonly and not limiting to the full scope of the present invention as setforth in the appended claims.

1. A pallet container comprising: (a) eight side walls, wherein saidside walls are joined to one another; (b) a first leg flap; (c) a firstinside fold and a second inside fold, wherein said first inside fold isjoined between said first leg flap and a first outside fold and saidsecond inside fold is joined between said first leg flap and a secondoutside fold; (d) a second leg flap; (e) a third inside fold and afourth inside fold, wherein said third inside fold is joined betweensaid second leg flap and a third outside fold and said fourth insidefold is joined between said second leg flap and a fourth outside fold;and (f) a first bottom flap joined to a second bottom flap to form abottom piece, wherein said first bottom flap has a first notch in itsfree end creating a first locking tab and said second bottom flap has asecond notch in its free end creating a second locking tab, wherein saidfirst notch and said first locking tab are interlocked with said secondnotch and said second locking tab.
 2. The pallet container of claim 1,wherein there is a first opening in the first bottom flap and a secondopening in the second bottom flap, wherein said first opening is capableof receiving a free end of said first leg flap and said second openingis capable of receiving a free end of said second leg flap.
 3. Thepallet container of claim 1 further comprising a locking mechanism,wherein said locking mechanism comprises: (a) a first locking piecejoined to said first bottom flap; (b) a first wall flap, wherein saidfirst wall flap is capable of receiving and securing said first lockingpiece
 4. The pallet container of claim 3, wherein said locking mechanismfurther comprises a second locking piece joined to said second bottomflap and a second wall flap, wherein said second wall flap is capable ofreceiving and securing said second locking piece.
 5. The palletcontainer of claim 3, wherein said first wall flap is cut into one ofsaid eight walls.
 6. The pallet container of claim 1 further comprisingat least one handle cut into one of said eight walls.
 7. The palletcontainer of claim 1 further comprising a top rim, wherein said top rimis comprised of eight top flaps joined to one another.
 8. The palletcontainer of claim 1 further comprising at least one slot cut into oneof said eight walls, wherein said slot is capable of securing a palletcontainer cap.
 9. A blank for making a pallet container comprising: (a)a first row comprising a plurality of vertical score lines defining aglue flap, a first wall, a second wall, a third wall, a fourth wall, afifth wall, a sixth wall, a seventh wall, and an eighth wall; and (b) asecond row comprising: (i) a glue flap, two leg flaps and two bottomflaps, wherein each of the two bottom flaps have a notch in their freeend creating a locking tab; and (ii) two inside folds joined on oppositesides of each of said two leg flaps and two outside folds abut each ofsaid bottom flaps on opposite sides.
 10. The blank of claim 9, whereineach of said two bottom flaps have an opening capable of receiving oneof said two leg flaps.
 11. The blank of claim 9 further comprising atleast one locking piece joined to one of said two bottom flaps.
 12. Theblank of claim 11 further comprising at least one wall flap, whereinsaid at least one wall flap is capable of receiving and securing atleast one locking piece.
 13. The blank of claim 12 wherein said wallflap is cut into one of said eight walls.
 14. The blank of claim 11further comprising at least one handle cut into one of said eight walls.15. The blank of claim 11 further comprising at least one top flapjoined to the top of one of said eight walls.
 16. The blank of claim 11further comprising at least one slot cut into one of said eight walls,wherein said slot is capable of securing a pallet container cap.
 17. Amethod of forming a pallet container, the method comprising the steps:forming a blank, the blank eight side walls, a first bottom flap, and asecond bottom flap, wherein the eight walls are connected by a pluralityof score lines; folding the eight walls inwardly along the plurality ofscore lines; securing the eighth wall to a flap associated with thefirst wall; and interlocking the first bottom flap and the second bottomflap, thereby forming a bottom piece of the pallet container.
 18. Themethod of claim 17, wherein there is a first opening in the first bottomflap and a second opening in the second bottom flap, wherein said firstopening is capable of receiving a free end of said first leg flap andsaid second opening is capable of receiving a free end of said secondleg flap, and wherein interlocking the first bottom flap and the secondbottom flap includes receiving of a free end of said first leg flap bysaid first opening and receiving of a free end of said second leg flapby said second opening.
 19. The method of claim 18, further comprisingthe step of folding the first and second free ends parallel to aninterior surface of the bottom piece of the container after interlockingthe first bottom flap and the second bottom flap.
 20. The method ofclaim 18, wherein the blank further includes first and second lockingtabs and first and second notches, and wherein the interlocking furtherincludes hooking said first locking tab into said first notch and saidsecond locking tab into said second notch.